3808616 Volvo.Penta Sensor

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-0914 Flywheel Guide Pin 2
B Forcing Screws 2
C 138-7575 Link Bracket 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The sensors must be backed off and the sensors must be reset to the correct dimension after the flywheel is installed.
Remove the guards from the space around the flywheel.
Disconnect the drive coupling from the flywheel.
Illustration 1 g00613228
Turn the crankshaft until the dash marks on the crankshaft and the flywheel face upward. This action will place the 3/4 inch tapped hole for Tooling (C) at the top of the flywheel.
Remove bolts (1) and (3). Install Tooling (A).
Install Tooling (C) and a suitable lifting device to flywheel (4). The weight of flywheel (4) is approximately 495 kg (1100 lb).
Remove the remaining bolts from the flywheel (4).
Raise Tooling (C) and a suitable lifting device in order to support the weight of the flywheel. Note: Do not pry against the aluminum seal because damage to the seal can occur.
Install Tool (B). Use the forcing screws to position the flywheel on the guide pins for removal. Note: Some flywheels do not have tapped holes for using forcing screws for removal. Pry between the rear housing and the back of the flywheel in order to move the flywheel onto the guide pins.
Remove flywheel (4) from Tooling (A).
Inspect the ring gear (5). If the ring gear replacement is necessary, remove the 24 bolts and the washers that hold ring gear (5) to the flywheel (4). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 8T-0914 Flywheel Guide Pin 2
B Forcing Screws 2
C 138-7575 Link Bracket 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 2 g00613228
Be sure that the mounting surface on the flywheel for the ring gear is free of the following conditions: clean, dry and free of nicks.
Install the new ring gear (5) on the flywheel (4). Install the ring gear. Orient the tooth chamfer toward the front of the engine. Install the bolt on weights in the original location. Note: Align the mark on the flywheel with the dash mark on the crankshaft.
Be sure that the timing mark on the crankshaft faces upward.
Install Tooling (A) in the crankshaft.
Install Tooling (C) and a suitable lifting device on flywheel (4). Note: Be sure that the mounting surfaces of the flywheel exhibit the following conditions: clean, dry and free of nicks.
Put the flywheel on Tooling (A), and check the alignment of the bolt hole. There are four unequally spaced holes on the back of the flywheel. These holes give clearance for the heads of the bolts that hold the seal adapter to the crankshaft. Be sure that the bolts are aligned.
Move the flywheel into position on the tooling.
Put 4C-5593 Anti-Seize Compound on the washer face and the bolt threads. Install the bolts. Remove Tooling (A) and install the remaining bolt (1) and the other bolt (3). Note: Do not use the timing pin to hold the crankshaft while you tighten the flywheel bolts. Remove the two front inspection covers on opposite sides of the crankcase. Place a board under the connecting rod in order to keep the crankshaft from turning. The board must measure 100 mm (4 inch) by 100 mm (4 inch).
Tighten the bolts to a torque of 800 80 N m (590 60 lb ft). Turn the bolts to an angle of 90° ( 15°). Note: Refer to the Specifications, SENR5527, "Flywheel Runout And Bore Runout".
Connect the drive coupling to the flywheel.
Install the flywheel guards.